Nonwoven fabrics having intercalated three-dimensional images

ABSTRACT

The present invention is directed to a method of forming a nonwoven fabric, which exhibits a plurality of three-dimensional images whereby the fabric is comprised of at least a first and second three-dimensional image that are dissimilar from one another. The three-dimensional images may be imparted into the fabric in a co-planar arrangement, multi-planar arrangement, or by utilizing both arrangements within the same fabric. Further, the present invention contemplates a fabric comprised of a plurality of three-dimensional images which can provide the fabric with various physical and/or aesthetic performances.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a division of U.S. Ser. No. 10/431,142, filed May 7,2003, which claims the benefit of priority Provisional Application No.60/378,728, filed May 8, 2003, the disclosures of which are incorporatedherein by reference.

TECHNICAL FIELD

The present invention relates generally to methods of making nonwovenfabrics, and more particularly, to a method of manufacturing a nonwovenfabric comprising a plurality of interposed three-dimensional imageswhereby the fabric incorporates at least a first and a secondthree-dimensional image, said first three-dimensional image exhibiting adifferent performance and/or aesthetic attribute than said secondthree-dimensional image, wherein said first three-dimensional image isimmediately presented within the second three-dimensional image.

BACKGROUND OF THE INVENTION

The production of conventional textile fabrics is known to be a complex,multi-step process. The production of fabrics from staple fibers beginswith the carding process whereby the fibers are opened and aligned intoa feedstock referred to in the art as “sliver”. Several strands ofsliver are then drawn multiple times on a drawing frames to; furtheralign the fibers, blend, improve uniformity and reduce the sliver'sdiameter. The drawn sliver is then fed into a roving frame to produceroving by further reducing its diameter as well as imparting a slightfalse twist. The roving is then fed into the spinning frame where it isspun into yarn. The yarns are next placed onto a winder where they aretransferred into larger packages. The yarn is then ready to be used tocreate a fabric.

For a woven fabric, the yarns are designated for specific use as warp orfill yarns. The fill yarns (which run on the y-axis and are known aspicks) are taken straight to the loom for weaving. The warp yarns (whichrun on the x-axis and are known as ends) must be further processed. Thelarge packages of yarns are placed onto a warper frame and are woundonto a section beam were they are aligned parallel to each other. Thesection beam is then fed into a slasher where a size is applied to theyarns to make them stiffer and more abrasion resistant, which isrequired to withstand the weaving process. The yarns are wound onto aloom beam as they exit the slasher, which is then mounted onto the backof the loom. The warp yarns are threaded through the needles of theloom, which raises and lowers the individual yarns as the filling yarnsare interested perpendicular in an interlacing pattern thus weaving theyarns into a fabric. Once the fabric has been woven, it is necessary forit to go through a scouring process to remove the size from the warpyarns before it can be dyed or finished. Currently, commercialhigh-speed looms operate at a speed of 1000 to 1500 picks per minute,where a pick is the insertion of the filling yarn across the entirewidth of the fabric. Sheeting and bedding fabrics are typically countsof 80×80 to 200×200, being the ends per inch and picks per inch,respectively. The speed of weaving is determined by how quickly thefilling yarns are interlaced into the warp yarns, therefore loomscreating bedding fabrics are generally capable of production speeds of 5inches to 18.75 inches per minute.

In contrast, the production of nonwoven fabrics from staple fibers isknown to be more efficient than traditional textile processes, as thefabrics are produced directly from the carding process.

Nonwoven fabrics are suitable for use in a wide variety of applicationswhere the efficiency with which the fabrics can be manufactured providesa significant economic advantage for these fabrics versus traditionaltextiles.

More recently, hydroentanglement techniques have been developed whichimpart images or patterns to the entangled fabric by effectinghydroentanglement on three-dimensional image transfer devices. Suchthree-dimensional image transfer devices are disclosed in U.S. Pat. No.5,098,764, which is hereby incorporated by reference; with the use ofsuch image transfer devices being desirable for providing a fabric withenhanced physical properties as well as an aesthetically pleasingappearance.

In circumstances whereby a single three-dimensional image is incapableor incongruous with satisfying the physical or aesthetic performancesrequired, an unmet need exists for a product which exhibits two or morethree-dimensional images, each image having different aesthetic orperformance attributes. Further, it has been found that a multi-stepfabrication process whereby a first image is imparted, followed by theapplication of a second image, is exceedingly problematic due to issuesof registering the two different images, and changes in the ability ofthe constituent fibrous matrix to receive pronounced changes inthree-dimensionality without obscuring the first imparted image. Inaddition, microporous drums, as well as, woven and/or embossed belts donot provide for sufficient finite fiber control to allow for thecreation of high quality, useable materials. It is, therefore, anobjective of the present invention to provide a method for manufacturinga nonwoven fabric whereby the fabric comprises at least a first and asecond three-dimensional image, said first three-dimensional imageexhibiting a different performance and/or aesthetic attribute than saidsecond three-dimensional image, wherein said first three-dimensionalimage is intercalated immediately within the second three-dimensionalimage. The nonwoven fabric of the present invention is suitable fornumerous home, medical and hygiene end-uses applications.

SUMMARY OF THE INVENTION

The present invention is directed to a method of forming a nonwovenfabric, which exhibits a plurality of three-dimensional images wherebythe fabric is comprised of at least a first and second three-dimensionalimage that are dissimilar from one another. The three-dimensional imagesmay be imparted into the fabric in a co-planar arrangement, multi-planararrangement, or by utilizing both arrangements within the same fabric.Further, the present invention contemplates a fabric comprised of aplurality of three-dimensional images which can provide the fabric withvarious physical and/or aesthetic performances, for example; the firstthree-dimensional image may provide a physical performance, such asexfoliation or particulate entrainment, and the second three-dimensionalimage may serves as an aesthetic enhancement. It is also within thepurview of the present invention that the first and secondthree-dimensional images may both provide a performance or an aestheticenhancement. A particular representative fabric whereby two separatethree-dimensional images, each image providing a different physicalperformance, are intercalated to form a material with a new or differentperformance is the combination of a first three-dimensional imageproviding exfoliation and a second three-dimensional image providingenhanced lather generation.

In accordance with the present invention, a method of making a nonwovenfabric includes the steps of providing a precursor web comprising afibrous matrix. While use of staple length fibers is typical, thefibrous matrix may comprise substantially continuous filaments. In aparticularly preferred form, the fibrous matrix comprises staple lengthfibers, which are carded and cross-lapped to form a precursor web. Inone embodiment, the nonwoven fabric is a composite or laminate structurewherein the precursor web is comprised of one or more additionalnonwoven layers, such as a support layer, a woven layer, such as a knit,or a film layer, such as a monolithic film.

In a particular embodiment envisioned by the present invention, theintercalated co-planar and/or multi-planar three-dimensional images ofthe resultant nonwoven fabric are adjoined to the background image ofthe fibrous substrate through fibrous bundles, referred to as fibroustransitions regions as specifically described in U.S. Pat. No. 5,674,591to James et al., which is hereby incorporated by reference.

In a third embodiment, the nonwoven fabric of the invention comprisestwo different intercalated three-dimensional images, wherein at leastone three-dimensional image comprises a repeating pattern of one or moreapertures. The apertures may extend entirely or partially through thesubstrate, and/or may be distributed in an organized fashion or randomlyscattered through out the resultant nonwoven fabric.

In a fourth embodiment, the nonwoven fabric of the invention comprisestwo different intercalated three-dimensional images, wherein one saidthree-dimensional image imparts a first woven or knit pattern and onesaid three-dimensional image imparts a different woven or knit pattern.For example, the present invention is capable of forming a nonwovenfabric having both left-hand and right-hand woven twill aestheticproperties interspersed throughout the continuous surface of the fabric,as represented in FIG. 16, or left-hand woven twill and tricot knitaesthetic properties, as represented in FIG. 17.

Subsequent to hydroentanglement, the three-dimensionally imaged fabricmay be subjected to one or more variety of post-entanglement performancemodifying treatments. Such treatments may include application of apolymeric binder composition, mechanical compacting, application ofsurfactant or electrostatic compositions, printing or dyeing, and likeprocesses.

Optionally, subsequent to three-dimensional imaging, the imaged nonwovenfabric can be treated with one or more performance or aestheticmodifying composition to further alter the fabric structure or to meetend-use article requirements. A polymeric binder composition can beselected to enhance durability characteristics of the fabric, whilemaintaining the desired softness and drapeability of thethree-dimensionally imaged fabric. A surfactant can be applied so as toimpart hydrophilic properties. In addition, electrostatic modifyingcompound can be used to aid in cleaning or dusting applications.

Other features and advantages of the present invention will becomereadily apparent from the following detailed description, theaccompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic view of an apparatus for manufacturing adurable nonwoven fabric, embodying the principles of the presentinvention;

FIG. 2 is a photomicrograph of the fabric herein described in thepresent invention;

FIG. 3 is a photomicrograph of the fabric herein described in thepresent invention;

FIG. 4 is a photomicrograph of the fabric herein described in thepresent invention;

FIG. 5 is a photomicrograph of the prior art nonwoven fabric;

FIG. 6 is a photomicrograph of the fabric herein described in thepresent invention;

FIG. 7 is a photomicrograph of the fabric herein described in thepresent invention;

FIG. 8 is a photomicrograph of the fabric herein described in thepresent invention;

FIG. 9 is a photomicrograph of the prior art nonwoven fabric;

FIG. 10 is a photomicrograph of the fabric herein described in thepresent invention;

FIG. 11 is a photomicrograph of the fabric herein described in thepresent invention;

FIG. 12 is a photomicrograph of the fabric herein described in thepresent invention;

FIG. 13 is a photomicrograph of the fabric herein described in thepresent invention;

FIG. 14 is a photomicrograph of the fabric herein described in thepresent invention;

FIG. 15 is a photomicrograph of the fabric herein described in thepresent invention;

FIG. 16 is a top plan view of an image transfer device having aleft-hand woven twill three-dimensional aesthetic property intercalatedwith a right-hand woven twill three-dimensional aesthetic property; and

FIG. 17 is a top plan view of an image transfer device having aleft-hand woven twill three-dimensional aesthetic property intercalatedwith tricot knit three-dimensional aesthetic property.

DETAILED DESCRIPTION

While the present invention is susceptible of embodiment in variousforms, there is shown in the drawings, and will hereinafter bedescribed, a presently preferred embodiment of the invention, with theunderstanding that the present disclosure is to be considered as anexemplification of the invention, and is not intended to limit theinvention to the specific embodiment illustrated.

The present invention is directed to a method of forming a nonwovenfabric comprised of a plurality of three-dimensional images comprisingat least a first three-dimensional image and a second three-dimensionalimage whereby the first and second three-dimensional images aredissimilar.

With reference to FIG. 1, therein is illustrated an apparatus forpracticing the present method for forming a nonwoven fabric. The fabricis formed from a fibrous matrix, which typically comprises staple lengthfibers, but may comprise substantially continuous filaments. The fibrousmatrix is preferably carded and cross-lapped to form a fibrous batt,designated F. In a current embodiment, the fibrous batt comprises 100%cross-lap fibers, that is, all of the fibers of the web have been formedby cross-lapping a carded web so that the fibers are oriented at anangle relative to the machine direction of the resultant web. U.S. Pat.No. 5,475,903, hereby incorporated by reference, illustrates a webdrafting apparatus.

The apparatus of the present invention includes a foraminous formingsurface in the form of a flat bed entangler 12 upon which the precursorweb P is positioned for pre-entangling. Precursor web P is thensequentially passed under entangling manifolds 14, whereby the precursorweb is subjected to high-pressure water jets 16. This process is wellknown to those skilled in the art and is generally taught by U.S. Pat.No. 3,485,706, to Evans, hereby incorporated by reference.

The entangling apparatus of FIG. 1 further includes an imaging andpatterning drum 18 comprising a three-dimensional image transfer devicefor effecting imaging and patterning of the now-entangled precursor web.The three-dimensional image transfer device of the present inventioncomprises at least two dissimilar images embedded within the imagingmovable surface. After pre-entangling, the precursor web is trained overa guide roller 20 and directed to the image transfer device 18, where aplurality of three-dimensional images are imparted into the fabric onthe foraminous forming surface of the device. The web of fibers isjuxtaposed to the image transfer device 18, and high pressure water frommanifolds 22 is directed against the outwardly facing surface from jetspaced radially outwardly of the image transfer device 18. The imagetransfer device 18, and manifolds 22, may be formed and operated inaccordance with the teachings of commonly assigned U.S. Pat. No.4,098,764, No. 5,244,711, No. 5,822,823, and No. 5,827,597, thedisclosures of which are hereby incorporated by reference. The entangledfabric can be vacuum dewatered at 24, and dried at an elevatedtemperature on drying cans 26.

The nonwoven fabric of the present invention may be a composite,laminate, single layer or multiple layers in order to incorporatesupport and/or absorbent mechanisms into the imaged fabric. Theplurality of three-dimensional images can provide the fabric withvarious attributes, for example, the first three-dimensional image mayprovide a performance attribute and the second three-dimensional imagemay serves as an aesthetic enhancement, the first and secondthree-dimensional images may both provide a performance, wherein the twodifferent images may have the same or different performance, or thefirst and second three-dimensional images may both provide for aestheticenhancement of the over all resultant nonwoven fabric.

The plurality of three-dimensional images intercalated within thenonwoven fabric can be arranged either co-planar to one another,multi-planar to one another, or arranged co-planar as well asmulti-planar to one another. Optionally, the intercalatedthree-dimensional images of the resultant nonwoven fabric can beadjoined to the background of the fibrous substrate or adjoined to anunderlying three-dimensional image through fibrous bundles, referred toas fibrous transitions regions as previously mentioned.

It is within the purview of present invention that the nonwoven fabriccan comprises two different intercalated three-dimensional images,wherein at least one three-dimensional image comprises a repeatingpattern of one or more apertures. The apertures may extend entirely orpartially through the substrate, and/or may be distributed in anorganized fashion or randomly scattered through out the resultantnonwoven fabric.

The nonwoven fabric can be further modified aesthetically throughsubsequent dyeing, and printing, or by using colored fibers during themanufacturing step, to achieve the affects of the desired nonwovenfabric.

Manufacture of a nonwoven fabric comprised of a plurality ofthree-dimensional images embodying the principles of the presentinvention is initiated by providing the fibrous matrix, which caninclude the use of staple length fibers, continuous filaments, and theblends of fibers and/or filaments having the same or differentcomposition. Fibers and/or filaments are selected from natural orsynthetic composition, of homogeneous or mixed fiber length. Suitablenatural fibers include, but are not limited to, cotton, reconstitutedcotton, wood pulp and viscose rayon. Synthetic fibers, which may beblended in whole or part, include thermoplastic and thermoset polymers.Thermoplastic polymers suitable for blending with dispersantthermoplastic resins include polyolefins, polyamides and polyesters. Thethermoplastic polymers may be further selected from homopolymers;copolymers, conjugates and other derivatives including thosethermoplastic polymers having incorporated melt additives orsurface-active agents. Staple lengths are selected in the range of 0.25inch to 10 inches, the range of 1 to 3 inches being preferred and thefiber denier selected in the range of 1 to 22, the range of 2.0 to 8denier being preferred for general applications. The profile of thefiber and/or filament is not a limitation to the applicability of thepresent invention.

From the foregoing, it will be observed that numerous modifications andvariations can be affected without departing from the true spirit andscope of the novel concept of the present invention. It is to beunderstood that no limitation with respect to the specific embodimentsillustrated herein is intended or should be inferred. The disclosure isintended to cover, by the appended claims, all such modifications asfall within the scope of the claims.

1. (canceled)
 2. (canceled)
 3. (canceled)
 4. (canceled)
 5. (canceled) 6.(canceled)
 7. A nonwoven fabric containing at least two intercalatedthree-dimensional images comprising: a nonwoven precursor web that isadvanced onto a three-dimensional image transfer device and that issubjected to hydraulic energy to entangle and impart into the web atleast a first three-dimensional image within a second three-dimensionalimage to form a nonwoven fabric containing at least two intercalatedthree-dimensional images, wherein a first three-dimensional imageprovides a performance attribute and a second three-dimensional imageprovides an aesthetic attribute
 8. A nonwoven fabric containing at leasttwo intercalated three-dimensional images comprising: a nonwovenprecursor web that is advanced onto a three-dimensional image transferdevice and that is subjected to hydraulic energy to entangle and impartinto the web at least a first three-dimensional image within a secondthree-dimensional image to form a nonwoven fabric containing at leasttwo intercalated three-dimensional images, wherein a firstthree-dimensional image provides a performance attribute and a secondthree-dimensional image provides a performance attribute.
 9. A nonwovenfabric in accordance with claim 8, wherein: the first three-dimensionalimage facilitates exfoliation and the second three-dimensional imageprovides enhanced lather generation.
 10. A nonwoven fabric containing atleast two intercalated three-dimensional images comprising: a nonwovenprecursor web that is advanced onto a three-dimensional image transferdevice and that is subjected to hydraulic energy to entangle and impartinto the web at least a first three-dimensional image within a secondthree-dimensional image to form a nonwoven fabric containing at leasttwo intercalated three-dimensional images, wherein a firstthree-dimensional image provides an aesthetic attribute and a secondthree-dimensional image provides a performance attribute.
 11. A nonwovenfabric containing at least two intercalated three-dimensional imagescomprising: a nonwoven precursor web that is advanced onto athree-dimensional image transfer device and that is subjected tohydraulic energy to entangle and impart into the web at least a firstthree-dimensional image within a second three-dimensional image to forma nonwoven fabric containing at least two intercalated three-dimensionalimages, wherein a first three-dimensional image provides an aestheticattribute and a second three-dimensional image provides an aestheticattribute.
 12. A nonwoven fabric containing at least two intercalatedthree-dimensional images made by steps comprising: a) providing anonwoven precursor web; b) advancing said nonwoven precursor web onto athree-dimensional image transfer device, which comprises at least twodissimilar images embedded within a movable imaging surface; c)subjecting the nonwoven precursor web to hydraulic energy tosimultaneously entangle and impart at least a first three-dimensionalimage within a second three-dimensional image into said web; and d)forming a nonwoven fabric havin at least two intercalatedthree-dimensional images, wherein a first three-dimensional imageprovides a performance attribute and a second three-dimensional imageprovides an aesthetic attribute.
 13. A nonwoven fabric in accordancewith claim 12, wherein: the step of subjecting the nonwoven precursorweb to hydraulic energy to simultaneously entangle and impart at least afirst three-dimensional image within a second three-dimensional imageinto said web comprises imparting three-dimensional images inarrangements selected from the group consisting of a co-planararrangement, a multi-planar arrangement, and mixtures thereof.
 14. Anonwoven fabric containing at least two intercalated three-dimensionalimages made by steps comprising: a) providing a nonwoven precursor web;b) advancing said nonwoven precursor web onto a three-dimensional imagetransfer device, which comprises at least two dissimilar images embeddedwithin a movable imaging surface; c) subjecting the nonwoven precursorweb to hydraulic energy to simultaneously entangle and impart at least afirst three-dimensional image within a second three-dimensional imageinto said web; and d) forming a nonwoven fabric having at least twointercalated three-dimensional images, wherein a first three-dimensionalimage provides a performance attrubute and a second three-dimensionalimage provides a performance attribute.
 15. A nonwoven fabric inaccordance with claim 14, wherein: the step of subjecting the nonwovenprecursor web to hydraulic energy to simultaneously entangle and impartat least a first three-dimensional image within a secondthree-dimensional image into said web comprises impartingthree-dimensional images in arrangements selected from the groupconsisting of a co-planar arrangement, a multi-planar arrangement, andmixtures thereof.
 16. A nonwoven fabric containing at least twointercalated three-dimensional images made by steps comprising: a)providing a nonwoven precursor web; b) advancing said nonwoven precursorweb onto a three-dimensional image transfer device, which comprises atleast two dissimilar images embedded within a movable imaging surface;c) subjecting the nonwoven precursor web to hydraulic energy tosimultaneously entangle and impart at least a first three-dimensionalimage within a second three-dimensional image into said web; and d)forming a nonwoven fabric havin at least two intercalatedthree-dimensional images, wherein a first three-dimensional imageprovides an aesthetic attribute and a second three-dimensional imageprovides an aesthetic attribute.
 17. A nonwoven fabric in accordancewith claim 16, wherein: the step of subjecting the nonwoven precursorweb to hydraulic energy to simultaneously entangle and impart at least afirst three-dimensional image within a second three-dimensional imageinto said web comprises imparting three-dimensional images inarrangements selected from the group consisting of a co-planararrangement, a multi-planar arrangement, and mixtures thereof.
 18. Anonwoven fabric containing at least two intercalated three-dimensionalimages made by steps comprising: a) providing a nonwoven precursor web;b) advancing said nonwoven precursor web onto a three-dimensional imagetransfer device, which comprises at least two dissimilar images embeddedwithin a movable imaging surface; c) subjecting the nonwoven precursorweb to hydraulic energy to simultaneously entangle and impart at least afirst three-dimensional image within a second three-dimensional imageinto said web; and d) forming a nonwoven fabric havin at least twointercalated three-dimensional images, wherein a first three-dimensionalimage provides an aesthetic attribute and a second three-dimensionalimage provides a performance attribute.
 19. A nonwoven fabric inaccordance with claim 18, wherein: the step of subjecting the nonwovenprecursor web to hydraulic energy to simultaneously entangle and impartat least a first three-dimensional image within a secondthree-dimensional image into said web comprises impartingthree-dimensional images in arrangements selected from the groupconsisting of a co-planar arrangement, a multi-planar arrangement, andmixtures thereof.